Ignition resistant mattress construction

ABSTRACT

An improved mattress construction which is resistant to ignition by a lighted cigarette, the improvement comprising an aluminum foil-substrate laminate interposed between the outer casing of said mattress and the yieldable interior thereof. It is preferred that the aluminum side of said aluminum foil-substrate laminate be in contact with the under-side of the outer casing. However, ignition resistance is also achieved when the substrate side is in contact with the outer casing. The aluminum foil-laminate is prepared by laminating aluminum foil to a woven or nonwoven textile material.

United States Patent [191 Woodruff [451 Dec. 31, 1974 1 1 IGNITION RESISTANT MATTRESS CONSTRUCTION [75] Inventor: Douglas Woodruff, Woodstock, I11.

[52] US. Cl. 5/345 R, 5/355, 5/361 B, [51] Int. Cl A47c 23/00, A47c 27/00 [58] Field of Search 5/345 R, 347, 355, 361 R,

5/361 B; 297/DIG. 5; 117/137 [56] References Cited UNITED STATES PATENTS 2,507,586 5/1950 Berkman 5/347 X 2,630,573 3/1953 Rand 2/1 2,726,977 12/1955 See et a1. 297/DIG. 5

2,770,816 11/1956 Reisner 5/355 2,801,427 8/1957 Crocker 297/D1G. 5

3,813,715 6/1974 Sooknc 5/355 3,818,520 6/1974 Richards 5/347 3,818,521 6/1974 Richards 5/347 Primary Examiner-Pau1 R. Gilliam Assistant Examiner-Andrew M. Calvert Attorney, Agent, or Firm.1ack Axelrood 5 7 ABSTRACT An improved mattress construction which is resistant to ignition by a lighted cigarette, the improvement comprising an aluminum foil-substrate laminate interposed between the outer casing of said mattress and the yieldable interior thereof. It is preferred that the aluminum side of said aluminum foil-substrate 1aminate be in contact with the under-side of the outer casing. However, ignition resistance is also achieved when the substrate side is in contact with the outer casing. The aluminum foil-laminate is prepared by laminating aluminum foil to a woven or nonwoven textile material.

15 Claims, 4 Drawing Figures PATENTED W13 1 1974 3. 857, l 26 saw u or i:

THE BLACK STAINS ARE CAUSED BY LIGHTED CIGARETTE BURNS IGNITION RESISTANT MATTRESS CONSTRUCTION Conventionally, a mattress comprises (1) an outer casing cover, generally called ticking, overlying (2) a padding comprising a layer of foamed polyurethane or foamed rubber (in a high quality mattress) or a layer of cotton felt or batting in a lower quality mattress, overlying (3) a yieldable interior filling or upholstery material which may be cotton batting, sisal, or the like, (4) a support or core which may consist of springs, foam padding, hair block, or other resilient material, and (5) a flange which circumscribes the inner perimeter of the mattress padding or yieldable interior filling and is composed of scrim. Scrim is usually made of loosely woven cotton, although it may also be made of a loosely woven or nonwoven synthetic resinous material such as polyester, nylon or the like. A lighted cigarette placed on top of a lower quality mattress, i.e., on the surface of the ticking, will burn through the ticking and through the cotton batting to the easily flammable filling thereunder where the smoldering cigarette sometimes causes the filling to burst into flame but most usually continues to smolder evolving toxic fumes. In the instance of a high quality mattress, the foamed polyurethane layer provides some flame or ignition retardancy. However, a lighted cigarette placed on the flange area of even a high quality mattress will burn down into the interior of the mattress along the channel afforded by the flange. In the past, many injuries and deaths, not to mention property damage, have occurred because of careless smoking in bed and the relative ease with which mattresses burn or smolder.

In a notice published in the Federal Register on June 7, 1972, the Department of Commerce recognized this hazard in the following language: a flammability standard was needed for mattresses to protect the public against unreasonable risk of the occurrence of fire leading to death, injury or property damage, arising from such hazards as continuous slow burning or smoldering of mattresses and the resultant production of smoke or toxic atmospheres. The Department of Commerce therefore promulgated standard DOC FF 4-72, Flammability Standard for Mattresses, (hereinafter referred to as the Federal Flammabilty Standard") to become effective June 7, 1973. After said date, all mattresses as defined in said Standard shall comply and meet the stringent safety provisions set forth therein.

In a mattress of higher quality, there is a foamed polyurethane layer situated directly underneath the outer casing or ticking. In most instances, this foamed polyurethane layer has enough inherent flammability resistance to pass that part of the Federal Flammability Standard which prescribes that a lighted cigarette be centrally placed on the ticking. However, even when present, the polyurethane layer terminates at the flange or edge of the mattress. The flange, as hereinbefore stated, is composed of scrim and provides support for the mattress construction to prevent sidewise slippage and to insure stability. Thus, the flange itself has no heat barrier properties or flammability resistance. When a lighted cigarette is placed on the ticking in the flange area, in accordance with the test method of the Federal Flammability Standard, it will burn through the ticking and through the flange (scrim) thereby contacting and burning the cotton and sisal filling underneath.

' tion, provides a channel or conduit through which the burning proceeds to the cotton and sisal underneath. For this reason, the flange area is a section of the mattress which is particularly conductive to conducting a spark or tire to the interior of the mattress by a wicking action.

It is therefore an object of this invention to provide an ignition resistant mattress construction which will pass the test of said Federal Flammability Standard and which will afford a greater measure of safety and pro tection against flammability than have the conventional mattresses of the prior art.

It is another object of the present invention to provide an ignition resistant flange construction for a mattress, which flange construction will provide a mattress which passes the test of said Federal Flammability Standard and which will afford a greater measure of safety and protection against flammability than have the conventional flanges of the prior art.

SUMMARY OF THE INVENTION The present invention provides an improved construction for a mattress which generally comprises an outer casing or ticking, a yieldable interior filling or upholstery material, a support core and a flange, the improvement comprising providing said flange as a laminate consisting essentially of aluminum foil laminated to scrim made from a woven or nonwoven material. This laminate is hereinafter referred to as aluminum foil-laminate." The aluminum side of said aluminum foil-laminate is preferably in contact with the undersurface of said outer casing. The aluminum foillaminate acts as a heat-dissipating medium which prevents a lighted cigarette from burning through to the interior filling. As previously noted, the aluminum foillaminate may also be placed with its aluminum side away from the outer casing.

In the instance where a mattress is constructed with a layer of flame resistant material immediately beneath the ticking, as for example a layer of polyurethane foam, the flange must be made resistant to ignition by a lighted cigarette since the flame or ignition resistant polyurethane does not extend into the flange area. The present invention therefore provides for a flame and ignition resistant flange for said mattress, said flange construction comprising a laminate of a scrim substrate and aluminum foil. The scrim may be composed of any suitable woven or nonwoven material. Preferably, the aluminum foil is in contact with the underside of said ticking, although the requisite flame retardancy is achieved when the scrim is immediately underneath the ticking. The flange is sewn around the perimeter of both the top and bottom mattress ticking and then fastened (hog-ringed) to the spring coils. The flange serves to stabilize the mattress and to prevent shifting or side-slipping of the top and bottom surfaces of the mattress. The aluminum foil-laminate functions to prevent a lighted cigarette from burning down to the readily ignitable interior filling of the mattress along the channel provided by the flange.

The following terms, as used herein, and as used in the Federal Flammability Standard, are defined as follows:

TICKING" means the outermost layer of Continued fabric or related material that encloses the mattress core and upholstery materials. means the main support system that may be present in a mattress, such as springs, foam or hair block. means all material, either loose CORE" TAPE EDGE" QUILTED' TUFTED The following definition of FLANGE has been proposed by The National Association of Bedding Manufacturers:

FLANGE" means that strip of woven or nonwoven material, generally inches wide, which is sewn around the perimeter of both the top and bottom ticking panels of the mattress. This flange is hogringed to the spring coils for support and serves the purpose of preventing shifting or sideslipping of the panels in relationship to the main structure of the mattress.

The outer casing or ticking may be of any suitable cloth or synthetic material such as nylon, rayon, acetate material and the like. The yieldable interior filling may be cotton felt or batting, foamed polyurethane or foamed rubber, sisal or hair, or combinations thereof.

The aluminum foil-laminate of the present invention which forms the heat-dissipating barrier to ignition by a lighted cigarette is formed by laminating aluminum foil to a woven or nonwoven substrate by means of any suitable adhesive or bonding agent. The woven substrate may be cotton, polyester, rayon, or nylon. The nonwoven substrate may be formed from rayon, nylon, polypropylene, polyester, or polyethylene.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I shows a perspective view, partially sectioned, of a mattress having a flange consisting of an aluminum foil-laminate.

FIG. 2 is an enlarged cross-sectional view of a flange comprising a cotton or polyester scrim layer laminated to aluminum foil.

FIG. 3 is an enlarged cross-sectional view of a mattress construction.

FIG. 4 depicts a portion of a mattress after cigarettes have burned their length in the flammability test.

Referring more specifically to the drawings, FIG. 1 depicts a mattress having an outer casing or ticking 2, and an inner support core comprising springs 3. Padding 4 is situated beneath ticking 2. Flange 5, composed of scrim laminated to aluminum foil, forms the perimeter of the interior of mattress 10. Border 8 circumscribes the entire mattress perimeter. Tape 6 secures the edge of flange 5 and the top of border 8 to ticking 2. Stitch line 7 secures flange 5 to ticking 2.

In FIG. 2, substrate 11 (scrim) is bondedor laminated to aluminum foil 13 by means of adhesive 12 to form flange 5.

In FIG. 3, ticking 2 covers urethane foam 4. Urethane foam 4 covers cotton felt 16 which overlies sisal 18. Flange 5 extends down and away from tape 6 and is connected to spring 20 by hog-ring 22. Border 8 encloses the perimeter of the mattress construction. Insulator 24 provides a buffer between spring 20 and sisal l8. Stitch line 7 secures flange 5 to ticking 2. Stitch line 7A binds the mattress together by securing tape 6, ticking 2, flange 5 and border 8.

As hereinbefore stated, the mattress construction of the present invention provides mattresses which meet the requirements of the FederalFlammability Standard. The method of this standard involves the exposure of the mattress surface to lighted cigarettes as the standard igniting source in a draft-protected environment, and the measurement of the ignition resistance of the mattress. These exposures include smooth, tape edge, and quilted or tufted locations, if they exist, on the mattress surface. Two-sheet tests are also conducted on similar surface locations. In the latter test, the burning cigarette is placed between two sheets.

The following excerpts from the Federal Flammability Standard sets forth the actual testing procedure employed:

TEST CRITERION. Testing the mattress surface in accordance with the testing procedure set forth in 0.4 Test procedure, individual cigarette test locations pass the test if the char length on the mattress surface is not more than 5.1 cm. (2 in.) in any direction from the nearest point of the cigarette. (In the interest of safety, the test operator should discontinue the test and record a failure before reaching the 2-inch char length if, in his opinion, an obvious ignition has occurred.)

0.4 TEST PROCEDURE (a) Apparatus (1) Test room. The test room shall be large enough to accommodate a full-scale mattress in a horizontal position and to allow for free movement of personnel and air around the test mattress. The room shall be equipped with a support system (platform, bench, etc.) upon which a mattress may be placed flat in a horizontal position at a reasonable height for making observations. For thin, flexible mattresses and mattress pads, the top surface of the support system shall be nonmetallic. The test area shall be draft protected and equipped with a suitable system for exhausting smoke and/or noxious gases produced by testing. The test room atmospheric conditions shall be between l827 C. (6580F.) and at less than 55 percent relative humidity.

IGNITION SOURCE. The ignition source shall be cigarettes without filter tips made from natural tobacco, i 2 mm. long with a tobacco packing density of 0.270 t 0.020 g/cm. and a total weight of 1.1 i 0.1 gm.

TESTING I) General. a. Light and place one cigarette at a time on the mattress surface. (If previous experience with the same type of mattress has indicated that ignition is not likely, the number of cigarettes which may be lighted and placed on the mattress at one time is left to the test operators judgement. The number of cigarettes must be carefully considered because a smoldering or burning mattress is extremely hazardous and difficult to extinguish.) If more than one cigarette is burning at one time, the cigarettes must be positioned no less than 6 inches apart on the mattress surface. Each cigarette used as an ignition source shall be well lighted but not burned more than 4 mm. (0.16 inch) when placed on the mattress. (Fire extinguishing equipment must be readily available at all times.)

b. If a cigarette extinguishes before burning its full length, the test must be repeated with a freshly lit cigarette on a different portion of the same type of location on the mattress surface until either (a) the number of cigarettes specified in 0.4(d) (l)c have burned their full lengths, (b) the number of cigarettes specified have extinguished before burning their full lengths, or (c) the number of cigarettes specified have resulted in failures according to 0.3(b) test criterion.

0. At least 18 cigarettes shall be burned on each mattress test surface. Nine in the bare mattress tests and nine in the two-sheet test. If three or more mattress surface locations (smooth surface, tape edge, quilted or tufted areas) exist in the particular mattress surface under test, three cigarettes shall be burned on each different surface location. If only two mattress surface locations exist in the particular mattress surface under test (tape edge and smooth surface), four cigarettes shall be burned on the smooth surface and five cigarettes shall be burned on the tape edge.

BARE MATTRESS TESTS -a. Smooth surfaces. Each burning cigarette shall be placed directly on a smooth surface location on thetest surface on the half reserved for bare mattress tests. The cigarettes should burn their full lengths on a smooth surface without burning across a tuft or stitching of a quilted area. However, if this is not possible because of mattress design, then the cigarettes shall be positioned on the mattress in a manner which will allow as much of the butt ends as possible to burn on smooth surfaces. Report results for each cigarette as pass or fail as defined in the test criterion.

b. Tape Edge. Each burning cigarette shall be placed in the depression between the mattress top surface and the tape edge, parallel to the tape edge on the half of the test surface reserved for bare mattress tests. If there is no depression at the edge, support the cigarettes in place along the edge and parallel to the edge with the straight pins. Three straight pins may be inserted through the edge at a 45 angle such that one pin supports the cigarette at a burning end, one at the center, and one at the butt. The heads of the pins must be below the upper surface of the cigarette. Report results for each cigarette as pass or fail as defined in the test criterion.

c. Quilted location. If quilting exists on the test surface, each burning cigarette shall be placed on quilted locations of the test surface. The cigarettes shall be positioned directly over the thread in the depression created by the quilting process on the half of the test surface reserved for bare mattress tests. If the quilt design is such that the cigarettes cannot burn their full length over the thread, then the cigarettes shall be positioned in a manner which will allow as much of the butt ends as possible to burn on the thread. Report results for each cigarette as pass or fail as defined in the test critenon.

d. Tufted location. lftufting exists on the test surface, each burning cigarette shall be placed on tufted locations of the test surface. The cigarettes shall be positioned so that they burn down into the depression caused by the tufts and so that the butt ends of the cigarettes burn out over the buttons or laces used in the tufts on the half of the test surface reserved for bare mattress tests. Report results for each cigarette as pass or fail as defined in the test criterion.

TWO-SHEET TESTS. Spread a section of sheet smoothly over the mattress surface and tuck under the mattress on the second half of the test surface, which has been reserved for the two-sheet test. Care must be taken that hems or any other portion of the sheet which is more than one fabric thickness, is neither directly under nor directly over the test cigarette in the twosheet test.

a. Smooth surfaces. Each burning cigarette shall be placed directly on the sheet covered mattress in a smooth surface location as defined in the bare mattress test. Immediately cover the first sheet and the burning cigarettes loosely with a second, or top sheet. Do not raise or lift the top sheet during testing unless obvious ignition has occurred or until the cigarette has burned out. (The extinguishment of the cigarette may be determined by holding the hand near the surface of the top sheet over the test location. If neither heat is felt nor smoke observed, the cigarette has burned out). If ignition occurs, immediately removed the sheets and ciga rette and follow the cautionary procedures outlined in the bare mattress test. Report results for each cigarette as pass or fail as defined in the test criterion.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The foregoing procedure for testing the flammability ofa mattress was followed using a mattress in which the flange consisted of a sheet of cotton scrim laminated to aluminum foil in which the aluminum side of the aluminum foil-laminate was in contact with the under surface of the ticking.

At the conclusion of the aforedescribed test, it was observed that there were burn chars having a length less than 2 inches with very little total damage to the ticking itself. The mattress was taken apart for examination of the interior. It was observed that for each cigarette there was no trace of a burn stain or discoloration immediately beneath the flange itself.

By way of contrast, a mattress having a conventional flange consisting of cotton scrim alone, when tested by the same method, displayed burn lengths in excess of 2 inches with charring and black discoloration and considerable destruction of the ticking itself together with severe charring of the cotton felt immediately beneath the flange. Upon taking the mattress apart for examination of the interior, it was observed that the destruction and burning caused by the lighted cigarettes were propagated deeply into the cotton felt filling of the mattress and, if not extinguished would have consumed the entire mattress.

I claim:

1. In a mattress construction comprising an outer casing, a yieldable interior filling having inherent flammability resistance to a lighted cigarette, a support core and a flange circumscribing the periphery of said mattress, the improvement which comprises providing said flange as a laminate of a scrim substrate and aluminum foil to render said mattress resistant to ignition by a lighted cigarette.

2. The mattress of claim I wherein the aluminum foil is laminated to a substrate selected from the group consisting of woven and nonwoven textile materials.

polypropylene.

8. The mattress of claim 2 wherein the substrate is polyethylene.

9. In a mattress construction comprising an outer casing, a yieldable interior filling having inherent flammability resistance to a lighted cigarette, a support core and a flange circumscribing the periphery of said mattress, the improvement which comprises providing said flange as a laminate of a scrim substrate and aluminum foil, the aluminum side aluminum foil-scrim laminate being in contact with the under-surface of said outer casing to render said mattress resistant to ignition by a lighted cigarette.

10. The mattress of claim 9 wherein the aluminum foil is laminated to a cotton substrate.

11. The mattress of claim 9 wherein the aluminum foil is laminated to a nylon substrate.

12. The mattress of claim 9 wherein the aluminum foil is laminated to rayon substrate.

13. The mattress of claim 9 wherein the aluminum foil is laminated to a polypropylene substrate.

14. The mattress of claim 9 wherein the aluminum foil is laminated to a polyethylene substrate.

15. The mattress of claim 9 wherein the aluminum foil is laminated to a polyester substrate.

l =l l 

1. IN A MATTRESS CONSTRUCTION COMPRISING AN OUTER CASING, A YIELDING INTERIOR FILLING HAVING INHERENT FLAMMABILITY RESISTANCE TO A LIGHTED CIGARETTE, A SUPPORT CORE AND A FLANGE CIRCUMSCRIBING THE PERIPHERY OF SAID MATTRESS, THE IMPROVEMENT WHICH COMPRISES PROVIDING SAID FLANGE AS A LAMINATE OF A SCRIM SUBSTRATE AND ALUMINUM FOIL TO RENDER SAID MATTRESS RESISTANT TO IGNITON BY A LIGHTED CIGARETTE.
 2. The mattress of claim 1 wherein the aluminum foil is laminated to a substrate selected from the group consisting of woven and nonwoven textile materials.
 3. The mattress of claim 2 wherein the substrate is polyester.
 4. The mattress of claim 2 wherein the substrate is cotton.
 5. The mattress of claim 2 wherein the substrate is nylon.
 6. The mattress of claim 2 wherein the substrate is rayon.
 7. The mattress of claim 2 wherein the substrate is polypropylene.
 8. The mattress of claim 2 wherein the substrate is polyethylene.
 9. In a mattress construction comprising an outer casing, a yieldable interior filling having inherent flammability resistance to a lighted cigarette, a support core and a flange circumscribing the periphery of said mattress, the improvement which comprises providing said flange as a laminate of a scrim substrate and aluminum foil, the aluminum side aluminum foil-scrim laminate being in contact with the under-surface of said outer casing to render said mattress resistant to ignition by a lighted cigarette.
 10. The mattress of claim 9 wherein the aluminum foil is laminated to a cotton substrate.
 11. The mattress of claim 9 wherein the aluminum foil is laminated to a nylon substrate.
 12. The mattress of claim 9 wherein the aluminum foil is laminated to rayon substrate.
 13. The mattress of claim 9 wherein the aluminum foil is laminated to a polypropylene substrate.
 14. The mattress of claim 9 wherein the aluminum foil is laminated to a polyethylene substrate.
 15. The mattress of claim 9 wherein the aluminum foil is laminated to a polyester substrate. 